Jigs



y 1962 R. A. SAHA 3,046,818

JIGS

Filed June 1, 1960 2 Sheets-Sheet 1 l2 g 24 I9 f Zy 1 INVENTOR. RICHARD A. SAHA HIS ATTORNEY July 31, 1962 R. A. SAHA 3,046,818

JIGS

Filed June 1, 1960 2 Sheets-Sheet 2 IN V EN TOR.

RICHARD A. SAHA HIS A TTORNE X it. Sttes tent tides Patented July 31, 1962 Filed June 1, 1960, Ser. No. 33,176 11 Claims. (Cl. 77-62) This invention relates to improved jigs utilized in connection with the assembly of tubular structural members. It is an object of the present invention to expedite and facilitate the utilization of tubular members in the construction of structures therefrom.

This application is a continuation-in-part of my copending application Serial Number 833,832, filed August 14,

Presently, many commercial installations are being made utilizing extruded tubular aluminum members for the jambs and frames of doorways and windows, respectively. The advantages of aluminum are well known in that it provides a construction requiring a minimum upkeep and, as a metal, is soft and relatively easy to work.

In many instances right angle connections must be made between such tubular members. These connections have heretofore been made utilizing clamps for properly aligning the members while they are joined. In commercial installations, where doorways may be as large as 7 feet by 8 feet or larger, this has required long clamps which are difficult to handle. The foregoing has necessitated the work of skilled mechanics increasing the labor cost. It is a further object of the present invention to provide a bracket constructed to facilitate a right angle connection between connected members so that less skilled mechanics may be utilized.

Previously, after the jambs had been correctly assembled and clamped together with the connectors, the necessary drilling between connectors and tubular members was done. It is another object of the invention to provide jigs for drilling the tubular members individually and without requiring that they be in the final assembled position.

Since the tubular members have had to be assembled in the final position before the drilling could take place,

it has been customary to assemble and clamp them in this position on the job site, which is not always convenient. Otherwise the assembled and clamped members had to be taken to the job site assembled. As is readily apparent, transporting an assembly of the tubular members of such dimensions can be a cumbersome afiair. With my jigs the assembly can be expeditiously performed on the job site utilizing tubular members and brackets that are correctly predrilled, if desired, or which may be drilled on the job site, if desired.

The aluminum tubular members are connected by a steel bracket having legs that are at an included angle between each other of 88 to 89. The leg of the bracket which is secured lastly is provided with holes that are offset from the cooperating holes in the tubular member for drawing the tubular members toward each other and tending to make a snug joint.

The holes in the tubular members for connecting the bracket thereto are formed by utilizing jigs. The jigs are positioned on the tubular members generally laterally by being provided with openings into which a rib of the tubular member extends. The jigs are provided with bent edge portions which are deformed to properly locate the jigs on the tubular members.

Assembly of the tubular members is accomplished by first determining where the joint is to be made. An indicating mark is made on one tubular member indicating the position of the other member thereon when the joint is finished. The one jig is placed on this tubular member and holes made to which the bracket will be connected. Holes are made in the other tubular member by utilizing the jig thereon also. The bracket is first secured by screws to an outside surface of one tubular member. The other tubular member is slipped over the bracket and secured by other screws to an inside surface to the other leg thereof. In tightening the screws between the second tubular member and the bracket, the oifset holes, and the included angle of between 88 and 89 tend to tighten the joint and insure that a right angle snug joint will result.

The foregoing and other objects of this invention, the principles of this invention, and the best modes in which T have contemplated applying such principles will more ully appear from the following description and accompanying drawings in illustration thereof.

In the drawings,

' FIG. 1 illustrates a partial side elevation of a frame for a doorway and a window overhead, a joint portion of which has been broken away to show the bracket in cross section;

FIG. 2 is a perspective view of the bracket;

PEG. 3 is a perspective view of a jig constructed in accordance with this invention;

FIG. 4 is a perspective view of a second jig constructed in accordance with this invention;

FIG. 5 is a top View of the jig illustrated in FIG. 3 operatively associated with a tubular member;

FIG. 6 is a perspective view of the jig illustrated in FIG. 4 but operatively associated with another tubular member; and

FIG. 7 is a perspective view illustrating the bracket assembled to one tubular member with the second tubular member about to be connected to the first member.

Referring to the drawings in detail, in FIG. 1, there are illustrated two vertical tubular members 11 bridged by a horizontal tubular member 32. The tubular members l1 and 12 are preferably extruded and formed from aluminum. The space below the longitudinal member and between the vertical member defines a space for a doorway, the tubular members serving as jambs thereof. Similarly, the space above the horizontal member 12 is utilized for a window. The horizontal member 12 has an approximately flat inner surface 14 of an upper wall 15 connected by a bracket 16 to the flat outer surface 19 of the left-hand wall 20. Preferably the bracket 16 is constructed of steel. The walls 15 and 20 are made integrally with outwardly extending ribs 22.

One bracket 16 is utilized at each joint between the horizontal member 12 and the vertical members 11 so that in the assembly illustrated in FIG. 1 two brackets 16 would be utilized. However, since the brackets and joints are substantially identical the subsequent description is in terms of only one bracket and one joint, it being understood the other is constructed substantially the same.

As illustrated, the bracket 16 has a vertical leg 24 that is longer than the horizontal'leg 26. The included angle A between the right-hand face and upper face, re-

spectively, of the legs 24 and 26 (which abut the tubular members 11 and 12) is between 88 and 89 tending to tighten the right angle joint between the horizontal member 12 and the vertical member 11. It has beenfound that steel brackets 16 having included angles below the specified range produced distortion of the aluminum tubular members 11 and 12. Included angles between 89 and 90 failed to produce sufiicient relative motion between tubular members 11 and 12 'to tighten the joint. The vertical leg 24 is provided with holes 30 large enough to allow the threaded portion of self-tapping screws 32 to enter without marring the threads thereof.

Both legs 24 and 26 of the bracket 16 are provided with slits or openings 28 for accommodating the rib 22 on the vertical member 11. The slit 28 completely divides the vertical leg 24 into two portions but the hori- 1 7) to cooperate with the holes 34 in the leg 26. The

holes 40 in the horizontal member 12 are large enough to allow the threaded portion of the screws 36 to pass there-' through without marring their threads and have countersunk outer portions, at 43, to accommodate the cone shaped underside of the fiat heads, so that the flat heads thereof may be turned flush with the wall. The horizontal member 12 is provided with slits 45 to accommo- 7 date the rib 22. i

The outer corner of the bracket 16 (between legs 24 and 26) is well rounded to prevent contact between the corner and any burrs that might be formed at the edge formed by surface 41 and the face 78 during cutting of the horizontal tubular member to size.

T o facilitate the drilling'of the holes 38 and 40, jigs 46 and 47 are provided.

The jig 46 is preferably formed from one piece of metal and includes a flat body portion 48 having longitudinal parallel edge portions 49 and 50. The jig '46 has end portions or lips 51 and 52 depending from the flat surface portion thereof. The end portion 51 is bent at substantially a right angle to the flat portion 48 and is provided with a threaded hole accommodating a thumb screw 53. A flat flexible leaf 54 (FIG. 3) is secured at one end portion to the lip 51 and the end of the screw 53 bears against a'flat portion of the leaf which is biased by the screw 53 against the side of the member 11, when the jig 46 is in the position illustrated in FIG. 5, to prevent the aluminum from being marred and to prevent cocking of the jig 46 with respect to the member 11 when the screw 53 is tightened. The lip 52 is turned to an angle of substantially less'than 90 between the portion 52 and the flat portion 48 and is provided with a flattened edge 61.

a Integrally with the edge portions 49 and 50, are handle 7 portions 55 and 56 flaring from the flat portion 48. The

handle portions 55 and 56 and the fiat portion 48 are provided with a slit 58 to accommodate the rib 22.

Holes are drilled in the flat portion 48 in which are driven bushings 60 having the diameter suitable for drilling holes 38, the bushings 60 being equi-spaced between the edges 49 and 50. Lateral positioning relative to the longitudinal axis of the tubular 11 is determined approximately by placing the rib 22 in the slit 58. The lateral spacing is determined accurately from the flattened edge 61 of lip 52. Bending the end portion 52 more or less will change the lateral position of the bushings 60.

g The jig 47 is similarly constructed from one pieceof metal and includes a flat portion 62 having end portions orlips 64 and 65. The portion 64 is bent at substantially a right angle to theflat body portion 62 and is provided with a flexible leaf 67 (FIG. 4) and a thumb screw 69, as and for the purposes described in connection with the jig 46. Also, the lip 65 is bent to form an included angle of less than 90 with respect to the flat portion 62 and has flattened edge for lateral positioning of the jig 47 similar to flattened edge'61 specified for jig 46.

V The jig 47 is provided with a longitudinal handle portion 72. A turned-down longitudinal portion 74 is bent to'form an angleof less than 90 with the flat portion 62. The flat portion 62 is provided with holes into which are driven bushings 76 suitable for use in drilling holes 40 in the horizontal member 12.

The portion 74 has a flattened edge 77 for abutting the end face 78 of the 4 horizontal member 12. The position of the bushings 76 from. the face 73 is determined accurately from the edge 77, by abutting the edge 77 with the end face 78 after the portion 74 has beenbent the proper amount. A slit 80 accommodates the rib 22 and provides approximate lateral placement, as for jig 46.

The bushings 76 are located with respect to the flattened edge 77 so the distance between their centers and the surface 19 of wall 20 (of the vertical member 11) is slightly greater, upon initial assembly, than the distance between the centers of the holes 34 (in the bracket 16) and the surface 19. This produces holes 40 and 34 that are offset slightly relative to each other but which are.

The offset between holes 4%} and 34 tends to draw the horizontal member 12' close enough to receive the screws.

toward the vertical member 11 upon assembly of. the

screws within holes 40 and 34. Preferably, the offset is about .025 inch. V

The foregoing bracket 16 and jigs 46 and 47=are utilized as follows: The vertical membersll are cut'to The horizontal member'12 is cut; to proper size, equal to the distance between opposed a predetermined size.

faces of the members 11, and with substantially flat end faces 78 that are perpendicular to the longitudinal axis of the tubular member 12.

The jig 47 is placed upon the end portion of the horizontal member 12,.as illustrated in FIG. 6, so that the rib 22 extends through slit 80 and the end portion 74 abuts theend face 78'0f the member 12 for properly spacing the bushings 76 from the end face. screw 69 is then tightened until the end portion 65 abuts the member 12 for accurately positioning the bushing laterally with respect to the longitudinal axis of the mernber 12 and the holes 40 drilled.

v Upon the vertical members 11, there is struck one or V more scribe lines 82, indicating the bottom, illustrated in FIG. 7, of the horizontal member 12 after the members are connected. 'The jig 46 is then positioned upon the member 11 so that the rib 22 extends through the slit 58 and the edge 49 is positioned on the lines 82. While the jig 46 is held in this position the thumb screw" 53 is tightened for accurately positioning the bushings laterally. The holes 38 are then drilled by utilizing bushings 60. v

If a line had been struck upon the member 11 indicating the top of the member 12 when in abutment with the vertical member 11, such line not being illustrated, then the top edgeof the jig would be aligned with this line.

Also, if a butt joint (not illustrated) in which the tubular member 11 terminates flush with the upper surface of wall 15 were being constructed, then the upper edge 50 would have been aligned with the end face (not illustrated) of.

the tubular member 11.

The jig 47 is positioned upon the ends of the horizontal member 12 so that the rib 22 extends through slit 80 and the edge 77 abuts the end face 78 of the member 12.

Thereafter, the thumb screw 69 is turned to secure the jig in position. The holes 40 are then drilled. In drilling these holes it sometimes happens that burrs are formed which extend beyond surface 14. The counter sinking 37 of holes 34 accommodates these burrs and en ables the major portion of the leg 26 to bebrought flush with the wall 15 when the screws 42 are turned fully, to insure a right angle joint. are drilled, the jigs 46 and 47 are removed, and the holes 40 countersunk. a i

The leg 24 of a bracket 16, previously constructed with the proportions, shape, etc. heretofore specified, is as:

sembled to the out surface 19 of the vertical member 11' by screws 32 which extend through 'holes30 and 38,

tapping threads as they are turned into hole 38. The head of the screws 32 has a flat underside and forces the vertical leg 24 to abut the surface 19. The horizontal tubular member 12 is then slipped over the bracket 16 so 7 that the surface 14 is upon the leg 26 and the screws 36 The thumb After the holes 38 and 40 was are placed through the holes 40 and 34. As mentioned, the holes if; and 34 are ofiset one from another and the angle between vertical and horizontal legs is between 88 and 89. During the turning of the screws 36 the horizontal tubular member 12 will be drawn toward the vertical tubular member 11 because of the oifset which tends to tighten the upper portion, as illustrated in FIG. 1, of the joint. Also, the vertical tubular member 11 will tend to pivot about the upper portion of the joint tending to tighten the lower portion of the joint.

Thus, from the foregoing it is seen that by the use of the jigs less skilled workers can perform the needed operations and the assembly. Further, the drilling of the members can be performed in the shop and need no longer be performed on the job site.

Having described the invention, I claim:

1. In a jig for forming holes in a tubular member having an upstanding portion, said jig including a body portion, said body portion having an opening for receiving said upstanding portion for positioning said jig in approximately the proper position, said body portion including means for indicating the position of the holes to be formed, said body portion having locating edge portions, and a fastening device secured to said body portion including depending lips and a screw for securing the jig to said tubular member.

2. The structure recited in claim 1 further defined by said means for forming said openings being spaced equidistant from said locating edge portions and wherein said edge portions are parallel to each other.

3. The structure recited in claim 2 and further including a surface generally perpendicular to said edge portions for locating said jig accurately relative to said work after said upstanding portion is received in said opening.

4. In a jig for forming holes in a tubular member htving an upstanding rib, said jig including a body por-' tion, said body portion having a slit for receiving said rib and positioning said jig in approximately the proper position, said body portion including means for indicating the position of the holes to be formed, said body portion having locating edge portions, said means being equi-spaced from said edge portion, and a fastening device secured to said body portion including depending lips and a screw for securing the jig to said tubular member.

5. The structure recited in claim 4 wherein the slit and the depending lips are generally parallel to each other and the locating edge portions are generally perpendicular to both the slit and the depending lips, whereby positioning and aligning of the jig on the work in transverse directions is facilitated after the upstanding rib is received loosely in said slit.

6. In a jig for forming holes in a tubular member having an upstanding rib and an end face, said jig including a body portion, said body portion having an opening through which said rib projects for positioning said jig in approximately the proper'position; said body portion including means for indicating the position of the holes to be drilled, said body portion including a lip bent at an angle to said body portion, the degree of bending of said lip portion controlling the positioning of said means from said end face, and a fastening device se- 8. The structure recited in claim 6 wherein the opening in the body and the depending lips extend in a direction parallel to each other and the bent lip for engaging the end face of the work extends generally perpendicular to both the opening in the body and the depending lips whereby positioning of the jig on the work in transverse directions is facilitated after the upstanding rib is received loosely in the said opening.

9. In a jig for forming holes in -a tubular member having an upstanding rib, said jig including a body portion, said body portion having an opening for receiving said rib; said opening and rib positioning said jig in approximately proper position, laterally to the longitudinal axis of said tubular member; said body portion including means for indicating the position of the holes to be formed, said body portion having locating edge portions, said means being equi-spaced from said edge portions, and a fastening device secured to said body portion including depending lips and a screw for securing the jig to said tubular member.

10. In a jig for forming holes in a tubular member having an upstanding rib and an end face, said jig including a body portion, said body portion having an opening for receiving said rib; said opening and rib positioning said jig in approximately proper position, later-ally to the longitudinal axis of said tubular member; said body portion including means for indicating holes, said body portion including a lip bent at an angle to said body portion, the degree of bending of said lip portion controlling the positioning of said means from said end face, and a fastening device secured to said body portion including a depending lip and a screw for securing the jig to said tubular member.

11. In a jig for forming holes in a work member having an irregular surface into association with which said jig will come for cutting holes into said work member, said jig including a body having bushings for indicating where the holes are to be cut in said surface, said body being disposed upon said work member portion during the cutting of the holes, said body including a guide portion to properly position said bushings in one direction, another portion of said body defining a space for receiving said irregular work surface portion in loose, interfitting relation for positioning said jig approximately correctly in the direction transverse to the direction previously mentioned and in abutment with the surface to be cut, and two positioning jig portions at least one of which is movable and extends transverse to said guide portion for accurately placing said jig in the transverse direction after said jig is first positioned approximately correctly upon the work due to said inter-fitting relation of a portion of the work and said space in the body of the jig and the other jig portion supporting means for fastening said jig to said work during the cutting of said holes.

References Cited in the file of this patent UNITED STATES PATENTS 2,641,147 Sule June 9, 1953 

